Can the ceramic tile industry become greener?

Viability analysis for the introduction of biomass in the industry energy mix

D. Gabaldón-Estevan, A. Mezquita, D. Alfonso

Daniel Gabaldón-Estevan | Chicago 22/04/2015Department of Sociology and Social Anthropology, Faculty of Social Sciences, University of Valencia- Valencia (ES) - daniel.gabaldon@uv.es

Index 0.

Introduction and motivation 1.

Theoretical framework 2.

Methods 3.

Results 4.

Discussion 5.

ESTIBMEIC Project - GV/2014/049

Socio-Technical Study on the Incorporation of Biofuels in the Energy Mix Ceramic Industry

Project financed by:

3

Nitrogen(agriculture)

Biodiversity(urbanization,agriculture)

Introduction: Ecological crisis: beyond the boundaries[Rockstrom et al., 2009. A safe operating space for humanity. Nature. 461, 472-475]

1.a

Environmental issues challenging the development of the ceramic tile industry[Gabaldón-Estevan, D.; Criado, E.; Monfort, E. (2014) The Green Factor in European Manufacturing: A case study of the Spanish ceramic tile industry. Journal of Cleaner Production 70, 242-250 ]

1.b

Environmental issues challenging the development of the ceramic tile industry[Gabaldón-Estevan, D.; Criado, E.; Monfort, E. (2014) The Green Factor in European Manufacturing: A case study of the Spanish ceramic tile industry. Journal of Cleaner Production 70, 242-250 ]

1.c

Energy consumption

- Tile industry is a big energy consumer (gas & electric).- Transition from oil to gas in the 80’s & new kilns reduced

firing times from 35-45 hours to 35-70 minutes. - Atomisers have cogeneration (total efficiency to 85-90%)

so further reductions in of carbon dioxide (CO2) and nitrogen dioxide (NO2) emissions more difficult.

Pollution

- Tile industry has done progress in substituting most of the hazardous elements that characterised production in the early industrialisation years. However there are still areas for improvement:

- Further reduce carbon dioxide (CO2).- Deal with elements as nitrogen dioxide (NO2), boron (B),

sulphur (S), sulphur dioxide (SO2), or fluorine (F).- And dust pollution, specially suspended particles due to

transportation.

What about this challenge?

6

A return to biomass? [ESTIBMEIC GV/2014/049 Socio-Technical Study on the Incorporation of Biofuels in the Energy Mix Ceramic Industry]

1.d

Peer-Effects in industrial agglomeration (Italy) [Istituto per la Promozione Industriale 2002, (based on ISTAT)]

2.a

Peer-Effects in industrial agglomerations (Spain) [El mapa dels districtes industrials d’España Conference by Joan Trullén, Castellón 28/06/2005]

2.b

5.

Evolutionary economics

FilièreLearning(know how, learning by

doing)

Knowledge networks

Institutional framework

Innovation system

District Innovation System

Productive specialization

District effect economies

Community & feeling of belonging

Interrelation & proximity

Theoretical framework: Applying the systemic approach to industrial districts[Gabaldón-Estevan, D.; Fernández de Lucio, I. and Molina Morales, FX. (2012) Distritual Innovation Systems. ARBOR-Ciencia pensamiento y cultura, 188 (753), pp. 63-73 ]

2.c

Population of companies centred on a productive activity (Bellandi, 2006; Coro & Micelli, 2007)

Human resources available and specialized (Sforzi, 2006; Sabel, 1982)

Tension and dynamism at the aglomeration (Brusco, 1990; Dei Ottati, 1994)

Easiness of both technological change and credit (Pyke y Sengenberger, 1992; Brusco, 1994)

[…] “socioterritorial entity characterised by the active presence of both a community of people and a group of companies on a natural and historically determined area . At the district […] the community and the companies tend to melt together”. (Becattini, 1992, pp. 62-63).

Marshallian Industrial district

ClusterIndustrial district

(Marshall, 1890)

(Becattini, 1979, 1986, 1992)

Feeling of belonging

Concentration & specialization

Competence & cooperation

Difficulties of appropriation

External economies

Theoretical framework: The influence of proximity on companies performance [Gabaldón-Estevan, D. (2011) El sistema distritual de innovación cerámico de Castellón. Universitat de València. Servei de Publicacions]

2.d

[…] “all important economic, social, political, organizational, institutional and other factors that influence the development, diffusion and use of innovations” (Edquist, 2004, pp. 182)

Sectoral systemof innovation

Technological systems

(Breschi and Malerba, 1997; Malerba, 2002)

(Carlsson and Stankiewitz, 1995; Huges, 1984; Callon, 1992)

Knowledge Heterogeneity Institutions Learning Interrelations

National systemof innovation

Regional systemof innovation

(Freeman, 1987; Lundvall, 1988, 1992; Nelson, 1993)

(Cooke, 1993 and 2001; Saxenian, 1985; Jaffe et al., 1993)

Evolutionist perspective

(Nelson and Winter, 1977 and 1982)

Functional approach

(Bergek et al., 2008; Jacobsson and Johnson, 2000;

Edquist, 1997)

DistrictInnovation system

(Gabaldon-Estevan et al., 2011)

Theoretical framework: Innovation is a collective and an interactive process[Gabaldón-Estevan, D. (2011) El sistema distritual de innovación cerámico de Castellón. Universitat de València. Servei de Publicacions

2.e

Legal and institutional framework

Technological and advanced services provider environment

Productive environment

Scientific environment

Method: identifying niches in which to stimulate further experiments and processes of experimentation that would contribute to lead the transition to a hypocarbon economy

3.

Adapted from Fernández et al. (1996)

9,3 %

90 ,3 %

0

5

10

15

20

25

30

Thermal energy consumption Electricity energy consumption

Ener

gy c

onsu

mpt

ion

(kW

h/m

2 )

13

Results: Energy consumption of the Spanish tile industry (2011) 4.a

14

Results: Thermal specific consumption (KWh/m2) by sub process (2007) 4.b

15

Results: CO2 emissions (kg CO2/t fired product) (2008) 4.c

Results: Identification of the target processes[Schematic illustration of the single-fired ceramic tile manufacturing process. Source ITC]

4.d

Raw materials

MillingSpray drying

Glazepreparation

Pressing Drying Glazing Firing

Floor tile

Wall tile

Raw materials

MillingSpray drying

Glazepreparation

Pressing Drying Glazing Firing

Floor tile

Wall tile

Most common ceramic tile manufacturing process in Europe (single-firing)

Thermal energy

Results: Identification of biomass potential [Tumuluru, J. S., Sokhansanj, S., Wright, C. T., Boardman, R. D., & Yancey, N. A. (2011, August). A review on biomass classification and composition, co-firing issues and pretreatment methods. In Proceedings of the 2011 ASABE annual international meeting. Louisville, Kentucky, USA (pp. 7-10).]

4.d

Areas of influence

Biomass sources

&

- Agricultural residues- Dedicated energy crops- Forestry- Industry- Parks and Gardens- Waste- Other (Roadside hay, Husks/Shells)

o The scientific community, UE, and other agents agree on demanding big changes on development strategies in order to reconfigure our societies according to sustainability;

o Limits to economic growth should be approached globally (think global, act at local/regional/national/sectorial or distritual)

o To achieve sustainability, far-reaching changes along different dimensions (technological, material, organisational, institutional, political economic and socio-cultural) have to occur, and an holistic approach that involve all agents is needed;

o We assume that district innovation systems can be conceived as complex systems where their social, economic, political, cultural, physical and environmental dimensions can be analysed as innovation systems the performance of which can be analysed and where changes can be elicited.

Discussion 5.a

Gabaldón-Estevan, D.; Mezquita, A.; Ferrer, S.: Monfort, E. (2014) Is European Union Environmental Policy Efficient at Promoting a Post-carbon Industry? The Case of Energy in the European Ceramic Tile Sector. Proceedings of the 11th ICIM 2014, Vaasa (Finland) 104-113 http://icim.vamk.fi/2014/uploads/UploadPaperDir/11thICIM2014.pdf

Mezquita, A.; Monfort, E.;Vaquer, E.; Ferrer, S.; Pitarch, J.M.; Arnal, M.A.; Cobo, F. (2014) Reduction of CO2-emissions in ceramic tiles manufacture by combining energy-saving measures. Cfi Ber. DKG 85, 91 (5) pp. E37-E42.

Monfort, E.; Mezquita, A.; Vaquer, E.; Gabaldón-Estevan, D. (2014) La evolución energética del sector español de baldosas cerámicas Bol. Soc. Esp. Ceram. V. 53 (3) 111-120http://boletines.secv.es/upload/2014070792201.201453111.pdf

Gabaldón-Estevan, D.; Criado, E.; Monfort, E. (2014) The Green Factor in European Manufacturing: A case study of the Spanish ceramic tile industry. Journal of Cleaner Production 70, 242-250 http://www.sciencedirect.com/science/article/pii/S0959652614001620

Gabaldón-Estevan, D.; Hekkert M.P. (2013) How Does the Innovation System in the Spanish Tile Sector Function? Bol. Soc. Esp. Ceram. V. 52 (3) 151-158 http://ceramicayvidrio.revistas.csic.es/index.php/ceramicayvidrio/article/download/1205/1239

Gabaldón-Estevan, D.; Fernández de Lucio, I. and Molina Morales, FX. (2012) Distritual Innovation Systems. ARBOR-Ciencia pensamiento y cultura, 188 (753), pp. 63-73 http://arbor.revistas.csic.es/index.php/arbor/article/download/1448/1457

Gabaldón-Estevan, D. (2011) El sistema distritual de innovación cerámico de Castellón. Universitat de València. Servei de Publicacions. http://rodrigo.uv.es/bitstream/handle/10550/23431/gabaldon.pdf?sequence=1

Monfort, E.; Mezquita, A.; Granel, R.; Vaquer, E.; Escrig, A.; Miralles, A.; Zaera, V. (2010) Analysis of energy consumption and carbon dioxide emissions in ceramic tile manufacture Bol. Soc. Esp. Ceram. V. 49 (4) pp. 303-310 http://boletines.secv.es/upload/20100901173134.201049303.pdf

Mezquita, A.; Monfort, E.; Zaera, V. (2009) Sector azulejero y comercio de emisiones: reducción de emisiones de CO2, benchmarking europeo. Bol. Soc. Esp. Ceram. V. 48(4) pp. 211-222 http://boletines.secv.es/upload/20090904100231.200948211.pdf

Tortajada Esparza, E.; Gabaldón-Estevan, D. and Fernández de Lucio I. (2008) La evolución tecnológica del distrito cerámico de Castellón: la contribución de la industria de fritas, colores y esmaltes. Bol. Soc. Esp. Ceram. V. 47 (2) pp. 57-80 http://boletines.secv.es/upload/20080512114901.47[2]57-80.pdf

Some of our references 5.b

Thank you for your attention!!!

Daniel Gabaldón-Estevan | Chicago 22/04/2014Department of Sociology and Social Anthropology, Faculty of Social Sciences, University of Valencia- Valencia (ES) - daniel.gabaldon@uv.es

https://uv.academia.edu/DanielGabald%C3%B3nEstevan

https://www.researchgate.net/profile/Daniel_Gabaldon-Estevan

https://www.linkedin.com/pub/daniel-gabad%C3%B3n-estevan/23/722/aaa

http://www.slideshare.net/DanielGabaldnEstevan

http://orcid.org/0000-0003-2086-5012

http://www.researcherid.com/rid/B-5195-2011

Epilog:

The end 5.b